Electric motor for laser-mechanical drilling

Abstract

A high power laser drilling system utilizing an electric motor laser bottom hole assembly. A high power laser beam travels within the electric motor for advancing a borehole. High power laser drilling system includes a down hole electrical motor having a hollow rotor for conveying a high power laser beam through the electrical motor.

What is claimed: 
     
       1. A high power laser electric motor assembly comprising:
 a. a first section attached with a second section; 
 b. the second section rotationally attached with a third section; 
 c. the first section comprising a means for receiving a high power laser beam, a means for collimating the laser beam, and a first fluid cavity; 
 d. the second section comprising an inner optical cavity and a second fluid cavity; 
 e. a laser beam path extending through the inner optical cavity of the second section, wherein the laser beam path is in a collimated space; and, 
 f. the third section comprising an optics assembly, and a third fluid cavity; 
 g. a first rotary sealing means sealing and attaching the first and second sections; 
 h. a second rotary sealing means sealing and attaching the second and the third sections; 
 i. wherein, the means for collimating the laser beam of the first section, the inner optical cavity of the second section and the optics assembly of the third section are in optical communication, and wherein the first fluid cavity, the second fluid cavity and the third fluid cavity are in fluid communication; and 
 j wherein the high power laser beam exits the means for collimating the laser beam of the first section, travels through the inner optical cavity of the second section along the laser beam path, and enters the optics assembly of the third section. 
 
     
     
       2. The assembly of  claim 1 , wherein the second section comprises an electric motor. 
     
     
       3. The assembly of  claim 2 , wherein the electric motor comprises a hollow rotor. 
     
     
       4. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 10 kW of power. 
     
     
       5. The assembly of  claim 4 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       6. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 80 kW of power. 
     
     
       7. The assembly of  claim 6 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       8. The assembly of  claim 6 , comprising a tractor. 
     
     
       9. The assembly of  claim 3 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       10. The assembly of  claim 9 , comprising a bent sub. 
     
     
       11. The assembly of  claim 10 , wherein the bent sub has an optical wedge assembly. 
     
     
       12. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source having greater than about 20 kW of power. 
     
     
       13. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source having greater than about 60 kW of power. 
     
     
       14. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source having greater than about 100 kW of power. 
     
     
       15. The assembly of  claim 3  wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source, and wherein the high power laser beam source comprises a plurality of high power lasers. 
     
     
       16. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source having greater than about 60 kW of power, and wherein the high power laser beam source comprises a plurality of high power lasers. 
     
     
       17. The assembly of  claim 3 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source having greater than about 80 kW of power, and wherein the high power laser beam source comprises a plurality of high power lasers. 
     
     
       18. The assembly of  claim 3 , comprising a bent sub. 
     
     
       19. The assembly of  claim 18 , wherein the bent sub has an optical wedge assembly. 
     
     
       20. The assembly of  claim 3 , comprising a tractor. 
     
     
       21. The assembly of  claim 2 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source. 
     
     
       22. The assembly of  claim 21 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       23. The assembly of  claim 22 , comprising a bent sub. 
     
     
       24. The assembly of  claim 23 , wherein the bent sub has an optical wedge assembly. 
     
     
       25. The assembly of  claim 2 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 10 kW of power. 
     
     
       26. The assembly of  claim 25 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       27. The assembly of  claim 2 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 80 kW of power. 
     
     
       28. The assembly of  claim 27 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       29. The assembly of  claim 27 , comprising a bent sub. 
     
     
       30. The assembly of  claim 29 , wherein the bent sub has an optical wedge assembly. 
     
     
       31. The assembly of  claim 2 , wherein the electric motor is a rare earth permanent magnet motor. 
     
     
       32. The assembly of  claim 31 , comprising a tractor. 
     
     
       33. The assembly of  claim 2 , comprising a bent sub. 
     
     
       34. The assembly of  claim 33 , wherein the bent sub has an optical wedge assembly. 
     
     
       35. The assembly of  claim 1 , wherein the inner optical cavity is in fluid isolation from the second fluid cavity. 
     
     
       36. The assembly of  claim 35 , wherein the first, the second or the third section comprise an electric motor. 
     
     
       37. The assembly of  claim 35 , comprising a bent sub. 
     
     
       38. The assembly of  claim 37 , wherein the bent sub has an optical wedge assembly. 
     
     
       39. The assembly of  claim 1 , wherein the second fluid cavity is formed between a rotor and a beam path tube. 
     
     
       40. The assembly of  claim 39 , wherein the first, the second or the third section comprise an electric motor. 
     
     
       41. The assembly of  claim 39 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source. 
     
     
       42. The assembly of  claim 41 , comprising a bent sub. 
     
     
       43. The assembly of  claim 42 , wherein the bent sub has an optical wedge assembly. 
     
     
       44. The assembly of  claim 39 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 10 kW of power. 
     
     
       45. The assembly of  claim 39 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 80 kW of power. 
     
     
       46. The assembly of  claim 39 , comprising a bent sub. 
     
     
       47. The assembly of  claim 46 , wherein the bent sub has an optical wedge assembly. 
     
     
       48. The assembly of  claim 1 , wherein the inner optical cavity is partially defined by a beam path tube. 
     
     
       49. The assembly of  claim 48 , wherein the first, the second or the third section comprise an electric motor. 
     
     
       50. The assembly of  claim 48 , comprising an electric motor having a hollow rotor. 
     
     
       51. The assembly of  claim 48 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source. 
     
     
       52. The assembly of  claim 48 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 10 kW of power. 
     
     
       53. The assembly of  claim 48 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 80 kW of power. 
     
     
       54. The assembly of  claim 1 , wherein the inner optical cavity is defined by a beam path tube. 
     
     
       55. The assembly of  claim 54 , wherein the first, the second or the third section comprise an electric motor. 
     
     
       56. The assembly of  claim 54 , comprising an electric motor having a hollow rotor. 
     
     
       57. The assembly of  claim 56 , comprising a bent sub. 
     
     
       58. The assembly of  claim 57 , wherein the bent sub has an optical wedge assembly. 
     
     
       59. The assembly of  claim 54 , comprising a bent sub. 
     
     
       60. The assembly of  claim 59 , wherein the bent sub has an optical wedge assembly. 
     
     
       61. The assembly of  claim 54 , comprising a tractor. 
     
     
       62. The assembly of  claim 1 , wherein the first, the second or the third section comprise an electric motor. 
     
     
       63. The assembly of  claim 1 , wherein the means for receiving the high power laser beam is in optical communication with a high power optical laser fiber that is in optical communication with a high power laser beam source. 
     
     
       64. The assembly of  claim 1 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 5 kW of power. 
     
     
       65. The assembly of  claim 1 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 10 kW of power. 
     
     
       66. The assembly of  claim 1 , wherein the means for receiving the high power laser beam is in optical communication with a conveyance structure that is in optical communication with a high power laser beam source having greater than about 80 kW of power. 
     
     
       67. The assembly of  claim 66 , comprising a bent sub. 
     
     
       68. The assembly of  claim 67 , wherein the bent sub has an optical wedge assembly. 
     
     
       69. The assembly of  claim 1 , comprising a bent sub. 
     
     
       70. The assembly of  claim 69 , wherein the bent sub has an optical wedge assembly. 
     
     
       71. The assembly of  claim 1 , comprising a tractor. 
     
     
       72. An electric motor laser bottom hole assembly drilling system comprising:
 a. a high power laser source, having the capability to provide a laser beam having a power of greater than about 50 kW; 
 b. an electrical power source; 
 c. a conveyance structure, 
 d. an electric motor bottom hole assembly; 
 e. the conveyance structure optically associating the high power laser source and the electric motor bottom hole assembly, and the conveyance structure electrically associating the electrical power source and the electric motor bottom hole assembly; 
 f. the electric motor bottom hole assembly comprising: an electric motor having a hollow rotor, and a laser-mechanical bit; and, 
 g. a laser beam path extending through the hollow rotor, whereby the laser beam from the laser source exits a collimating optic, transmits through the laser beam path in a collimated space of the hollow rotor, and enters a rotating optical package coupled to a laser-mechanical bit. 
 
     
     
       73. The system of  claim 72 , wherein the laser beam path in the hollow rotor is in the collimated space. 
     
     
       74. The system of  claim 73 , comprising a bent sub having an optical wedge assembly. 
     
     
       75. The system of  claim 73 , wherein the conveyance structure comprises three high power optical fibers. 
     
     
       76. The system of  claim 73 , wherein the conveyance structure comprises four high power optical fibers. 
     
     
       77. The system of  claim 73 , wherein the laser source is capable of providing a laser beam having a power of at least about 90 kW and the conveyance structure comprises five high power optical fibers. 
     
     
       78. The system of  claim 72 , wherein the laser beam path in the hollow rotor is partially contained in a free space. 
     
     
       79. The system of  claim 72 , comprising a bent sub having an optical wedge assembly. 
     
     
       80. The system of  claim 72 , wherein the conveyance structure comprises three high power optical fibers. 
     
     
       81. The system of  claim 72 , wherein the conveyance structure comprises four high power optical fibers. 
     
     
       82. The system of  claim 72 , wherein the laser source is capable of providing a laser beam having a power of at least about 90 kW and the conveyance structure comprises five high power optical fibers. 
     
     
       83. The system of  claim 72 , comprising a tractor. 
     
     
       84. An electric motor laser bottom hole assembly drilling system comprising:
 a. a high power laser source, having the capability to provide a laser beam having a power of greater than about 50 kW; 
 b. an electrical power source; 
 c. a conveyance structure, 
 d. an electric motor bottom hole assembly; 
 e. the conveyance structure optically associating the high power laser source and the electric motor bottom hole assembly, and the conveyance structure electrically associating the electrical power source and the electric motor bottom hole assembly; 
 f. the electric motor bottom hole assembly comprising: a first optical package, a second optical package, an electric motor having a hollow rotor, and a laser-mechanical bit, wherein the first optical package comprises a collimating optic; 
 g. a beam path tube partially within the hollow rotor and optically and sealingly associating the first optics package and the second optics package; 
 h. the second optical package optically associated with the laser-mechanic bit; and, 
 i. a laser beam path extending through the beam path tube, whereby the laser beam from the laser source exits the first optical package, transmits through the collimating optic, travels along the laser beam path extended through the beam path tube in a collimated space, and enters the second optical package coupled to the laser-mechanical bit. 
 
     
     
       85. The system of  claim 84 , comprising a tractor. 
     
     
       86. A system for performing high power laser operations comprising:
 a. a high power laser source; 
 b. a high power laser fiber in optical association with the high power laser source; 
 c. the high power laser fiber in optical communication with a first optical package in an electric motor laser bottom hole assembly; 
 d. the first optical package in optical communication with a second optical package through a laser beam path between the first and second optical packages; and, 
 e. the laser beam path being at least partly located within a section of an electric motor where rotation takes place upon operation of the electric motor and a laser beam exits the first optical package, travels through a collimate space along the laser beam path, and enters the second optical package. 
 
     
     
       87. A method of laser-mechanical directional drilling comprising:
 a. providing an electric motor laser bottom hole assembly system to a borehole at a borehole site, the system comprising an electric motor laser bottom hole assembly and a high power laser source, the electric motor bottom hole assembly comprising a pair of optical wedges; 
 b. lowering the laser bottom hole assembly into the borehole; 
 c. configuring the optical wedges to define an angled laser beam path; 
 d. delivering a high power laser beam having at least about 20 kW to the electrical motor laser bottom hole assembly, wherein the high power laser beam exits a first optical wedge of the configured optical wedges, transmits through the angled laser beam path in a collimated space, and enters a second optical wedge of the configured optical wedges; 
 e. wherein the angled beam path correlates with a directional drilling path and whereby the borehole is advanced along the directional drilling path. 
 
     
     
       88. A method of advancing a borehole comprising:
 providing a system for performing high power laser operations comprising:
 a. a high power laser source; 
 b. a high power laser fiber in optical associating with the high power laser source; 
 c. the high power laser fiber in optical communication with a first optical package in an electric motor laser bottom hole assembly; 
 d. the first optical package in optical communication with a second optical package through a laser beam path between the first and second optical packages; and, 
 e. the laser beam path being at least partly located within a section of an electric motor where rotation takes place upon operation of the electric motor and the laser beam exits the first optical package, travels through the laser beam path in a collimated space, and enters the second optical package; 
 
 lowering the system into a borehole and rotating the electric motor while propagating the laser beam through the electric motor bottom hole assembly to thereby advance the borehole.